Injection Valve with Indexing Mechanism

ABSTRACT

A flapper valve preferably used in injection application in deep subterranean locations has an actuating sleeve with a seat to accept an object. A j-slot connects the actuation sleeve movement to the housing so that with an object on the seat and an applied pressure cycle the sleeve moves the flapper to the open position. The plug is dissolved and the injection begins. The plug can have an opening so as to allow continuous injection flow as the flapper is operated. Closing the flapper involves a second object on the same seat and a pressure cycle so that a spring can push the sleeve away from the flapper to allow a torsion spring on the flapper to close it.

FIELD OF THE INVENTION

The field of this invention is valves for subterranean use that areactuated with an indexing mechanism and more particularly flapper typevalves actuated with pressure cycles on a plug that can be removed afteruse.

BACKGROUND OF THE INVENTION

Various valve designs used in the past have incorporated sleeves indexedby j-slot devices to selectively align and misalign ports. In oneexample the ball that lands on a seat to allow application of pressurecycles to operate the j-slot is blown through the seat after a change invalve position. This is illustrated in U.S. Pat. No. 7,416,029. Anotherdevice is in essence a sliding sleeve that allows flow uphole and thesleeve, which is mounted to a j-slot, can be cycled from uphole as flowfrom uphole acts to close a flapper on top of the sleeve for pressurecycling. This is shown in US Publication 2008/0196898.

Other designs use a j-slot to unlock a lock in conjunction with a plugthat can then disappear as illustrated in U.S. Pat. Nos. 5,765,641;6,119,783 and 6,026,903. Other designs use relatively movable mandrelcomponents where cycles of picking up and setting down weight actuate aj-slot to operate a flapper, as shown in U.S. Pat. No. 4,458,762. Somedesigns use a j-slot to unlock a lock so that a flapper can thenoperate. A plug is landed on a seat which then is dissolved. Someexamples of combinations of some of these features are U.S. Pat. Nos.7,270,191; 6,904,975 and US Publication 2009/0242199.

Other designs provide a flowpath constriction to create differentialpressure on a flow tube to open a flapper. These designs such as the MCInjection Valves from Halliburton and the A Series Injection Valve fromSchlumberger restrict access through the valve for advancing othertools. The Model J Wireline Retrievable Injection Valve from BakerHughes opens on a predetermined flow through a restriction. Somehydraulically operated safety valves had a feature to lock a flapperopen after the flapper was displaced with a flow tube driven by ahydraulic piston. In this design shown in U.S. Pat. No. 6,902,006 theflame holding the flapper was itself shifted when the flapper was opento catch the edge of the flapper in a top groove of a sleeve below. Yeta few other applications that use flow bore restrictions to create aforce to move a tube to open a flapper are U.S. Ser. Nos. 12/433,134,filed on Apr. 30, 2009 entitled Innovative Flow Tube, 12/469,310, filedon May 20, 2009, entitled Flow-Actuated Actuator, and 12/469,272, filedon May 20, 2009, entitled Flow-Actuated Actuator and Method.

The present invention deals with flapper type valves with a preferreduse in injection service. The design provides a way of operating theflapper without control lines. In deep applications there will be highhydrostatic pressure in the control line that would have to be offsetwith a very large return spring. While a dual control line system canoffset this hydrostatic effect in deep applications there is additionalexpense and operational issues from doubling up the control lines andrunning them with a string into the subterranean location. In thepreferred embodiment there is no need for control lines. A flapper isoperated by a sleeve that responds to pressure cycles against a seatedball or plug to push the flapper open after a predetermined number ofcycles. The ball, plug or other object is removed from its blockingposition on a seat preferably by dissolving it so that flow cancommence. The preferred application is injection service where water,salt water, chemicals, CO₂ or steam can be the flowing fluid. When it isdesired to close the flapper another object can be landed in the sameseat and the cycling with pressure repeated to allow a return spring toraise the flow tube so that a torsion spring on the flapper pivot canmove the flapper to the closed position against its seat. As few as asingle application and removal of pressure cycle can be used to changethe flapper position between open and closed.

In an alternative embodiment an actuation sleeve pushes the flapper openas well as engaging or contacting a counter sleeve below that is engagedto a j-slot. On release of pressure a return spring on the countersleeve raises it to retain the flapper in the open position while aseparate return spring biases the actuation sleeve up. A second ball orother object landed in the seat of the actuation sleeve once againdisplaces the actuation sleeve against the counter sleeve. This time thecounter sleeve is held against its return spring by the j-slot so thaton release of pressure the torsion spring on the flapper allows theflapper to pivot closed when the actuation sleeve is also pushed up byits return spring. After a use of either the first or the second object,either is removed preferably by dissolving to get either object out ofthe flow path.

The dissolving of the object can occur by fluids such as water,saltwater in the wellbore, acid added to the wellbore, or by otherreactive or dissolving agents present or added to the wellbore. Otherways to fail the object to get it out of the flow path are alsocontemplated.

Those skilled in the art will better appreciate the scope of theinvention from a review of the description of the preferred embodimentand the associated drawings while recognizing that the full scope of theinvention is determined by the appended claims.

SUMMARY OF THE INVENTION

A flapper valve preferably used in injection application in deepsubterranean locations has an actuating sleeve with a seat to accept anobject. A j-slot connects the actuation sleeve movement to the housingso that with an object on the seat and an applied pressure cycle thesleeve moves the flapper to the open position. The plug is dissolved andthe injection begins. The plug can have an opening so as to allowcontinuous injection flow as the flapper is operated. Closing theflapper involves a second object on the same seat and a pressure cycleso that a spring can push the sleeve away from the flapper to allow atorsion spring on the flapper to close it. In an alternative embodimentan actuation sleeve pushes a counter sleeve that is movable through aj-slot. The first object on the actuation sleeve pushes both sleevessuch that removal of pressure allows the now open flapper to be retainedin the open position and the object to be dissolved or otherwiseremoved.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a section view with the flapper closed;

FIG. 2 is the view of FIG. 1 after the object is landed on the actuationsleeve and the sleeve is displaced to compress the return spring;

FIG. 3 shows the object dissolved and the passage through the sleevecleared;

FIG. 4 is an unrolled view of the track for the j-slot for the actuationsleeve;

FIG. 5 is the flapper closed view for run in using an alternativeembodiment that moves an actuation sleeve against a counting sleevewhere the counting sleeve is on a j-slot;

FIG. 6 is the view of FIG. 5 with an object on the seat on the actuationsleeve and both sleeves displaced as pressure is applied;

FIG. 7 is the view of FIG. 6 with applied pressure removed and theobject dissolved showing the counting sleeve holding the flapper open;

FIG. 8 is an unrolled version of the counting sleeve j-slot trackshowing a straight lower end; and

FIG. 9 is an alternative embodiment to FIG. 8 where the lower end of thecounting sleeve is scalloped to enhance the amount of protrusion overthe flapper when the flapper is retained in the open position.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1 has a housing 10 with a passage 12 and a flapper 14 that pivotson a pin 16. A torsion spring 18 biases the flapper 14 toward the closedposition against the seat 20. An actuating sleeve 24 is slidably mountedin the passage 12 to move against the bias of a return spring 26 when anobject such as a ball or plug 28 lands and obstructs the passage 12 atseat 30 as shown in FIG. 2. A pin or screw 32 extends into a j-slottrack 34 that is shown rolled open in FIG. 4. The j-slot track 34 has aseries of long passages 36 and short passages 38 that alternate. In theFIG. 1 position, the actuating sleeve 24 is at its highest locationwhere spring 26 is extended and the flapper 14 is biased by spring 18against the seat 20. This can happen because the actuating sleeve 24 inFIG. 1 is not in contact with the flapper 14. In essence the spring 26advances the actuating sleeve 24 until the long passage 36 hits the pin32, as shown in FIG. 1.

Dropping the object 28 onto seat 30 and applying pressure moves thesleeve 24 axially and initially without rotation as the long passage 36with pin 32 extending into it guides the axial movement. When the pinadvances to passage 40 there is rotation of the sleeve 24 as the pinenters passage 42 and remains there as long as pressure is held againstthe object 28. When the pressure is removed in passage 12 on the object28 the sleeve 24 reverses direction and resumes rotation as the pin 32rides in passage 44 on the way to passage 38. This is the FIG. 2position.

The object 28 is then removed from the seat 30 in one of a variety ofways such as dissolving, chemical reaction, melting, or being ejectedthrough the seat 30. Note that the sleeve 24 has been pushed down tocontact the flapper 14 and rotate it 90 degrees so that in FIG. 2 it isbehind the sleeve 24 with the spring 26 being compressed. The positionof FIG. 2 is held because the pin 32 in short passage 38 is at the endof that passage with the sleeve 24 under a spring force. FIG. 3 is theview of FIG. 2 after the object 28 is no longer on the seat 30.Injection of fluid down passage 12 or production in the oppositedirection can now take place as indicated by arrow 46.

Those skilled in the art will appreciate that a single application andremoval of pressure cycle has gotten the flapper 14 to go from closed toopen and that the landing of a second object (not shown) on seat 30followed by a pressure cycle of application and removal of pressure willget the pin 32 into the next long passage 36 to allow the sleeve 24 torise up and away from the flapper 14 so that the torsion spring 18 canclose the flapper 14 against its seat 20. While the j-slot 34 isdesigned for a single cycle of pressure application and removal to movethe flapper 14 the j-slot 34 can be designed for multiple cycles beforethe flapper moves. Since the second object (not shown) lands on the sameseat 30, it can have the same shape as the object 28.

As an option to avoid stopping injection when trying to close theflapper while landing a second object (not shown) on seat 30, a smallpassage 46 (illustratively shown on object 28 but is actually used inthe second object that is not shown) is put in so that there is someinjection flow through it but the pressure difference across the objectis sufficient to move the sleeve 24 so that it can be raised whenpressure is removed so that the flapper 14 can close. If such a passageis used it is preferred that the object shape not be round but insteadbe a cylindrical plug for example so that the passage 46 is in fluidcommunication with the passage 12 when the object (not shown) lands onseat 30 as the second landed object.

FIGS. 4-9 show an alternative embodiment. Here there is an actuatingsleeve 124 biased by a spring 126 but with no j-slot mechanism. Asbefore there is a flapper 114 on a pivot 116 that has a torsion spring118. The flapper seats on seat 120. Below the flapper 114 there is acounting sleeve 50 biased by a spring 52. A pin 54 extends into a j-slot56 that is shown rolled out in FIGS. 8 and 9. When the first object 128lands on seat 130 and pressure is applied in passage 112 the actuatingsleeve 124 is pushed down to compress the spring 126 and to push theflapper 114 90 degrees to the open position behind the sleeve 124 asshown in FIG. 6. That same movement of sleeve 124 that opened theflapper 114 has resulted in the lower end 58 hitting the upper end 60 ofthe counting sleeve 50 and pushing it in tandem with sleeve 124 whilecompressing the spring 52. In the FIG. 5 position the pin 54 is in theshort passage 62. As pressure is applied to the object 128 the sleeve 50initially moves axially without rotation as pin 54 guides the passage 62until passage 64 is reached at which time there is translation androtation followed by translation only as the passage 66 runs past thepin 54. Once the pressure in passage 112 is let off the object 128, thespring 126 pushes up sleeve 124, while the spring 52 pushes up sleeve50. Sleeve 50 initially only translates down as pin 54 tracks path 66 inthe opposite direction before going into path 68 which causes the sleeve50 to advance axially while rotating until pin 54 reaches path 70 wherethere is only axial motion of sleeve 50 without rotation. The upper end60 of sleeve 50, while initially moving in tandem with sleeve 124, stopsmoving when the upper end 60 is in front of the flapper 114 so thatrotation of the flapper from the open position is prevented. The sleeve124 moves away from the now stationary sleeve 50 until the sleeve 124resumes its original position. These movements are illustrated in FIG. 7which also shows that the initial object 128 has been removed using anyof the techniques described before. Flow in passage 112 can now occur asindicated by arrow 72. As before, dropping a second object on seat 130and another pressure cycle gets the device back to the FIG. 5 positionand the second object (not shown) can then be removed using thepreviously described techniques.

FIGS. 8 and 9 are identical except for the variation of FIG. 9 having ascalloped end 74 having peaks 76 and alternating valleys 78. Thisfeature extends the reach of the sleeve 50 toward the flapper 114 whenthe pin 54 is in the long slots 70.

Those skilled in the art will appreciate that the device eliminated theneed for a hydraulic control system including control lines and a pistonto move the sleeves for operating the flapper. The springs in the designsimply offset the weight of the sleeve that they bias independent of thedepth of the application. The passage is cleared after the operation ofthe flapper so that preferably injection can take place with the flapperheld open. A second object can be used to release the flapper so it canclose. A passage in the object can be optionally provided to continueinjection flow with the object being seated. Dissolving the object withan introduced fluid is the preferred way to reopen the flowpath.

The above description is illustrative of the preferred embodiment andmany modifications may be made by those skilled in the art withoutdeparting from the invention whose scope is to be determined from theliteral and equivalent scope of the claims below:

1. A barrier valve for subterranean use, comprising a housing having apassage extending between opposed ends thereof and a valve membermovable between an open position where said passage is open and a closedposition where said passage is closed; an actuation sleeve in saidpassage, actuable with at least one application of pressure in saidhousing acting on said sleeve when a flowpath in said sleeve istemporarily obstructed, to move axially and operate said valve memberbetween said open and closed positions.
 2. The valve of claim 1,wherein: said flowpath is blocked by at least one object delivered intosaid passage.
 3. The valve of claim 2, wherein: said valve membercomprises a flapper.
 4. The valve of claim 3, wherein: said sleevedisplaces and holds said flapper to said open position by at least onecycle of applied and removed pressure.
 5. The valve of claim 3, wherein:said sleeve comprises a seat; said at least one object comprises a firstobject to temporarily obstruct said flowpath when said first object ison said seat.
 6. The valve of claim 5, wherein: said sleeve is guided insaid housing by a j-slot assembly and movement of said sleeve responsiveto pressure on said first object when said first object is on said seatovercomes a biasing member in said housing.
 7. The valve of claim 6,wherein: said j-slot is configured to maintain said sleeve in positionwhere said flapper is in said open position upon at least oneapplication and removal of pressure on said first object when saidobject is on said seat.
 8. The valve of claim 7, wherein: said firstobject is removed from blocking said seat with said flapper retainedopen by one of melting, dissolving, or chemical reaction.
 9. The valveof claim 8, wherein: said at least one object comprises a second objectthat blocks said flowpath after said first object is removed from saidseat in said sleeve and application and removal of pressure to saidsecond object allows said biasing member to move said sleeve away fromsaid flapper to allow said flapper to move to said closed position. 10.The valve of claim 9, wherein: said second object is removed fromblocking said seat with said flapper open by one of melting, dissolving,or chemical reaction.
 11. The valve of claim 9, wherein: said secondobject comprises an elongated shape, said elongated shape having a paththerethrough to allow flow through said second object during at leastone application of pressure that shifts said sleeve, whereupon at leastone pressure removal on said second object, said flapper closes.
 12. Thevalve of claim 9, wherein: said first and second objects comprisespheres.
 13. The valve of claim 2, wherein: said at least one objectcomprises an elongated shape, said elongated shape having a paththerethrough to allow flow through said object during at least oneapplication of pressure that shifts said sleeve when said valve memberis open, whereupon at least one pressure removal, said valve membercloses.
 14. The valve of claim 3, further comprising: a counting sleevedisposed on an opposite side of said flapper from said actuation sleeve,said counting sleeve selectively positioned to retain said flapper insaid open position.
 15. The valve of claim 14, wherein: said actuationsleeve contacting said counting sleeve after moving said flapper to theopen position.
 16. The valve of claim 15, wherein: said actuation sleevecomprises a seat; said at least one object comprises a first object totemporarily obstruct said flowpath when said first object is on saidseat.
 17. The valve of claim 16, wherein: pressure applied to said firstobject on said seat moves said sleeves in tandem after said sleeves makecontact.
 18. The valve of claim 17, wherein: said counting sleeve isbiased against movement caused by said actuation sleeve; said countingsleeve operably connected to said housing with a j-slot assembly andfurther comprises an upper end defining a recess adapted to retain saidflapper in said open position.
 19. The valve of claim 18, wherein: atleast one cycle of pressure application and removal on said first objectallows said j-slot to position said recess to retain said flapper insaid open position.
 20. The valve of claim 19, wherein: said actuationsleeve is biased against pressure application to said first object,whereupon at least one removal of pressure from said first objectinitially moves said sleeves in tandem until said j-slot stops saidcounting sleeve with said recess in position to block movement of saidflapper at a time when said flapper is still held open by said actionsleeve.
 21. The valve of claim 20, wherein: said first object is removedfrom blocking said seat with said flapper retained open by one ofmelting, dissolving, or chemical reaction. said at least one objectcomprises a second object selectively in contact with said seat afterremoval of said first object and application of at least one cycle ofapplication and removal of pressure on said second object allows saidj-slot to retain said recess away from said flapper while said bias onsaid actuation sleeve moves said actuation sleeve away from said flapperto allow said flapper to close.
 22. The valve of claim 21, wherein: saidsecond object is removed from blocking said seat with said flapper openby one of melting, dissolving, or chemical reaction. said second objectcomprises an elongated shape, said elongated shape having a paththerethrough to allow flow through said second object during at leastone application of pressure that shifts said actuation sleeve, whereuponat least one pressure removal on said second object, said flappercloses.
 23. The valve of claim 14, wherein: said at least one objectcomprises an elongated shape, said elongated shape having a paththerethrough to allow flow through said object during at least oneapplication of pressure that shifts said actuation sleeve when saidvalve member is open, whereupon at least one pressure removal, saidvalve member closes.
 24. The valve of claim 22, wherein: said first andsecond objects comprise spheres.
 25. The valve of claim 18, wherein:said counting sleeve has an undulating upper end which extends the depthof said recess that engages the flapper to retain said open position.